ERP system in the production of equipment, how to keep records of positions in production?

Question

ERP

There is such a question. A manufacturing company with several factories (it takes place in Germany). Now the transition to a common ERP system is underway. The question concerns only the accounting of manufactured products in production and warehouse goods for this.
The problem is that in production, in addition to purchased items, which are easily accounted for, they also use parts produced at the enterprise itself. For example, a sheet of metal is taken, bought at a cost of X1, cut to size on machine A1, processed on machine A2, bent on machine A3, painted on machine A4. Then it goes through the assembly in manual mode in time N.
The problem is that now these data are entered by operators, in fact, manually, and at such a pace, the complete transition of the enterprise to accounting through ERP will take 5 years, if not all 10. The number of parts produced is several thousand only at the head enterprise.
There are two tasks
1. You need to get the full and very accurate cost of the product at the output, taking into account not only the cost of raw materials, which can be more or less quickly calculated, but also the employment of machine tools, many of which are very expensive and the cost of their work is many times higher than the cost of raw materials .
2. Plan the fulfillment of orders with control of available positions and timely production of missing parts by the required date. Those. we entered into the ERP system an order for product B, which is already fully entered into the ERP in the form of a list of parts produced in production and items purchased from outside. After that, the purchase items are purchased by the purchasing department, and the parts produced in the enterprise are produced IF they are not in stock in advance and just in time for the start of production of this item Q.
Question 1. How can I quickly make lists of items? How is it done in other large enterprises?
In German, such a list of positions is called Stückliste, in English - stocklists or parts list. And such a list includes not only the name of the part, but the entire process of manufacturing the part from the metal sheet at the input to the finished part. Then a machine is assembled from such parts, which also has its own stocklist.
So far, my idea is that the parts move from one point in the production to another only after marking the QR code with the automatic accounting in the system. But maybe there is another solution? Any non-contact markers that will be automatically read? Does anyone have such experience?
Question 2. Can you please tell me the address of an English, German or Russian language ERP forum where I can ask the same question and find some solution.

Answer 1

For example, a sheet of metal is taken, bought at a cost of X1, cut to size on machine A1, processed on machine A2, bent on machine A3, painted on machine A4. Then it goes through the assembly in manual mode in time N.

This is called the specification and flow chart, and the first describes the consumption of raw materials in the second operation performed (indicating the equipment involved). The degree of detail depends on the wishes that they want to take into account. In particular, they describe the stage / redistribution, the duration of employment.
but in general the functionality of the MES system.
the described issues are resolved in modern systems, including reading data from equipment, using barcodes and other reflections of the release ..
I don’t know about you, but in Russia this is the fashion https://v8.1c.ru/erp/ basically read it. The technique is the same, the technical implementation is different.
Search for how your automation systems are presented and send your questions to them. Let them show you how they do it. So choose what to buy * / implement ..

Answer 2

I can suggest. Your task can be perfectly reduced to LP (linear programming) and will perfectly fall on graphs. There is more than enough in the textbooks of the undergraduate program in Operations Research and Decision Making.

Answer 3

1. Accurate cost accounting is impossible and does not make sense. This is a tradition that made sense a hundred years ago when manual labor prevailed.
2. How to do what in your ERP you need to ask a question to ERP implementers. Most likely, we are talking about SAP
in each decision is decided in its own way, which will give you a general answer